QLTY07011 2009 Lean Management Techniques
Full Title
Lean Management Techniques
Transcript Title
Lean Management Techniques
Code
QLTY07011
Attendance
N/A %
Subject Area
QLTY - Quality
Department
MENG - Mech. and Electronic Eng.
Level
07 - Level 7
Credit
05 - 05 Credits
Duration
Semester
Fee
€
Start Term
2009 - Full Academic Year 2009-10
End Term
9999 - The End of Time
Author(s)
Noeleen Grant
Programme Membership
SG_EQUAL_J07 200900 Bachelor of Science in Quality
SG_EENGI_B07 200900 Bachelor of Science in Engineering Management
SG_EQUAL_B07 200900 Bachelor of Science in Quality Engineering
Description
This module aims to give the student the necessary skills to apply Lean tools and techniques in a workplace environment .
Lean focuses on identifying and eliminating waste (non-value added activities) through the entire process. In this course, students will learn Lean concepts such as value stream mapping, standardisation of work, error-proofing, visual signals and pull systems.
Learning Outcomes
On completion of this module the learner will/should be able to;
1.
Describe the benefits of applying "Lean Management" techniques in a manufacturing or service environment
2.
Identify the seven forms of waste in a production process
3.
Map out the steps necessary when implementing or helping others implement a Lean Management program
4.
Construct a Current and Future Value Stream map with associated material and information flows
5.
Implement a Lean 5S program
6.
Describe the key elements of a TPM program
7.
Describe and Perform an SMED analysis
8.
Design a solution to a Poka-Yoke type problem
9.
Identify and Calculate a set of appropriate metrics for a lean process.
10.
Describe the principles underlying the Theory of Constraints (TOC)
11.
Implement a Lean Visualisation Program
12.
Prepare a Kaizen even
Module Assessment Strategies
Indicative Practicals/Projects
Value Stream Mapping of Automation (RIM 21) Lab
Lean Simulations - Pull Systems
Poka - Yoke Error Proofing Practicals
SMED Practicals in Lab
Implementation of Lean Visualisation tools in Automation (RIM 21) Lab
Indicative Syllabus
This subject aims to give the student the necessary skills to apply Lean Management techniques in a workplace environment. Lean is a systematic approach to manage customer relations, the supply chain, product development and production operations.
Syllabus Content
1. Principles of Lean Management
- How lean can improve quality, reduce cycle time and reduce WIP.
- Identify Waste in your process - The 7 Deadly Wastes
- Standardisation of work
- Lean in a service environment
2. Lean Value Stream Mapping
- Value Stream MappingTM (current state)
- Value Stream MappingTM (future state)
- Information flow
- Material flow
- WIP
- Process Map
3. Lean 5S System
- Concepts of 5 S system
- Seiri - (Sort) Segregate and Discard
- Seiton - (Straighten) Arrange and Identify for Ease of Use
- Seiso - (Scrub) Clean Daily
- Seiketsu - (Systematise) Revisit Frequently
- Shitsuki - (Standardise) Motivate to Sustain
4. Productive Maintenance
- TPM Principles, Goals & Methods
- Elimination of equipment related waste
- Overall Equipment Efficiency (OEE) measurement
- Autonomous Maintenance
- Equipment Management
5. Lean Set up Reduction (SMED)
- Single Minute Exchange of Dies (SMED) system
- Apply four-step changeover improvement process to achieve set-up reduction
6. Lean Poka-Yoke (Error Proofing)
- Error Proofing Steps
- Designing and implementing Poka-Yoke systems
7. Lean Metrics
- Cycle Time / Lead Time
- Takt Time
- Heijunka (Load Levelling)
8. Theory of Constraints (TOC)
- Push Vs Pull
- Kanban
- JIT
- Production Levelling / Continuous Flow
9. Lean Visualisation
- The Visual Workplace
- Visual Controls
10. Kaizen Events
- Why use Kaizen
- Kaizen Workshop Stages
Coursework & Assessment Breakdown
Coursework & Continuous Assessment
50 %
End of Semester / Year Formal Exam
50 %
Coursework Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Continuous Assessment Lab assignment,Practical work and project work | Coursework Assessment | UNKNOWN | 50 % | OnGoing | 1,2,3,4,5,6,7,8,9,10,11,12 |
End of Semester / Year Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Final Exam final written examination | Final Exam | UNKNOWN | 50 % | End of Year | 1,2,3,4,5,6,7,8,9,10,11,12 |
Part Time Mode Workload
| Type | Location | Description | Hours | Frequency | Avg Workload |
|---|---|---|---|---|---|
| Lecture | Distance Learning Suite | Theory | 1.5 | Weekly | 1.50 |
| Workshop / Seminar | Engineering Laboratory | Various Lean Workshops | 4 | Once Per Semester | 0.27 |
| Independent Learning | UNKNOWN | Moodle Activities | 5 | Weekly | 5.00 |
Total Part Time Average Weekly Learner Contact Time 1.77 Hours
Module Resources
Non ISBN Literary Resources
|
Authors |
Title |
Publishers |
Year |
|
Michael L. George, John Maxey, David T. Rowlands |
The Lean Six Sigma Pocket Toolbook, ISBN-10: 0071441190 |
McGraw-Hill |
2004 |
|
Angeli, Bob et al |
The Lean Pocket Guide, ISBN 0-9725728-0-5 |
MCS Media |
2003 |
|
Jeffrey Liker |
The Toyota Way Field Book |
McGraw-Hill |
2003 |
|
John Bicheno |
Lean Toolbox |
Buckingham: PICSIE |
2000 |
|
Bruce Henderson |
Lean Transformation |
Oaklea Press |
2002 |
|
Eliyahu M. Goldratt |
The Goal, ISBN-10: 0884271781 |
North River Press; 3RD edition |
2004 |
Other Resources
On Moodle